Raytherm 133-4001 Manual

I STALLATIO & OPERATI G
I STRUCTIO S
CATALOG NO. 2000.50AF ffective: 01-06-10 Replaces: 02-24-09 P/N 240035 Rev. 33
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
Models 133–4001
Type H
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
WAR I G: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury or loss of life. Refer to this manual.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids or other combustible materials in the vicinity of this or any other appliance. To
do so may result in an explosion or fire.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
Raytherm™
Heating
Boilers

2
Rev. 33 reflects the following:
Changes to: Model Identification on page 5, Boiler Types on page 6, floor shield information on page 7, Single Boiler
Primary/Secondary Piping diagram on page 19, Multiple Boiler - Reverse Return Hook-Up diagram on page 20, Low Water
Cut-Off and High and Low Gas Pressure Switch instructions on page 23.
Additions: xpanded “Operating Controls” section on pages 21-23 to cover all modes, Manual and Auto Reset High Limit
instructions on page 23,.
Deletions: Diaphragm Tank System diagram on page 19, Multi-zone Heating Systems diagram on page 20.

WAR I GS 4
Pay Attention to These Terms 4
MODEL IDE TIFICATIO 5
RECEIVI G EQUIPME T 6
CERTIFICATIO S 6
BOILER TYPES 6
Type H1 - Mechanical Modulating 6
Type H2 - Motorized Modulating 6
Type H3 - 2-Stage Controls 6
Type H4 - On-Off Controls 6
Type H5 - Mechanical Modulating 6
Type H9 - 4-Stage 6
I STALLATIO 7
Installation Codes 7
Installation Base 7
Clearances 7
Outdoor Boilers 8
High-Wind Conditions (Outdoor Units Only)8
Combustion and Ventilation Air 8
(Indoor Units Only) 8
Venting 9
Indoor Installations 10
Vent Piping 13
Vent Damper Installation 15
Plumbing 16
Gas Supply Connections 16
CO TROLS 21
conomaster Controls 21
lectronic Ignition 21
Operating Controls 21
Limit Controls 23
ELECTRICAL CO ECTIO S 24
START-UP 25
Before Start-Up 25
General 25
CO TE TS
3
Filling System - Heating Boilers 25
thylene Glycol Systems -
Heating Boilers 25
Initial Start-Up - Pump And Motor 25
For Models with Automatic Gas Valves 28
After Start-Up 28
Standing Pilot Checkout
Procedure 28
Intermittent Pilot System
Checkout (S8600) 28
Inspections 29
Burners 29
Controls 29
Suggested Inspection Schedule 29
LOW Ox BOILERS 30
Models 181 to 401 30
Operation 30
Start-Up (S8600M) 30
Blower Adjustment 30
Visual Inspection 30
lectrical 30
Flame Roll-Out Safety Switch 31
Service 31
Burner Tray Removal 31
Gas Valve Removal 31
Main Burner and Orifice Removal 31
Pilot Removal 32
Combustion Fan Removal 32
TROUBLESHOOTI G 33
Service 38
Repair Section 38
REPLACEME T PARTS 41
WARRA TY 42

4
DA GER: Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
WAR I G: Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
CAUTIO : Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
OTE: Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
DA GER: Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
WAR I G: Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
WAR I G: Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
WAR I G: To minimize the possibility of improper
operation, serious personal injury, fire, or damage to
the heater:
• Always keep the area around the heater free of
combustible materials, gasoline, and other
flammable liquids and vapors.
• Heater should never be covered or have any
blockage to the flow of fresh air to the heater.
WAR I G - CALIFOR IA PROPOSITIO
65: This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.
WAR I G: Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
CAUTIO : This heater requires forced water
circulation when the burner is operating. See
minimum and maximum flow rates. Severe damage
will occur if the heater is operated without proper
water flow circulation.
CAUTIO : Operation of this heater in low
temperature systems requires special piping.
Harmful internal condensation will occur if the inlet
water temperature does not exceed 105°F. Warranty
claims will be denied when condensation occurs.
CAUTIO : If this heater is to be installed above
radiation level, it must be provided with a low water
cut-off device at the time of heater installation.
CAUTIO : If this heater is to be installed in a
negative or positive pressure equipment room, there
are special installation requirements. Consult factory
for details.
WAR I GS—Pay Attention to These Terms
WAR I G: This unit contains refractory ceramic
fiber (RCF) insulation in the combustion chamber.
RCF, as manufactured, does not contain respirable
crystalline silica. However, following sustained
exposure to very high temperatures (>2192F), the
RCF can transform into crystalline silica
(cristabolite). The International Agency for Research
on Cancer (IARC) has classified the inhalation of
crystalline silica (cristabolite) as carcinogenic to
humans.
When removing the burners or heat exchangers,
take precautions to avoid creating airborne dust and
avoid inhaling airborne fibers. When cleaning spills,
use wet sweeping or High fficiency Particulate Air
(H PA) filtered vacuum to minimize airborne dust.
Use feasible engineering controls such as local
exhaust ventilation or dust collecting systems to
minimize airborne dust. Wear appropriate personal
protective equipment including gloves, safety
glasses with side shields, and appropriate NIOSH
certified respiratory protection, to avoid inhalation of
airborne dust and airborne fiber particles.

5
MODEL
IDE TIFICATIO
The model number of a boiler can be found on the
Sales Order and the boiler's rating plate. The example
below identifies what the characters of the model num-
ber represent.
MODEL NUMBER EXAMPLE:
H 3 - 0 5 1 4 A
Series
Model Size
Representative of approximate MBTUH input
(Model 0514 has input of 511,500 BTUH)
Firing Mode
1 Mechanical Modulation
2 Motorized Modulation
3 2-Stage Firing
4 On-Off Firing
5 Low Temperature Mechanical Modulation
9 4-Stage Firing
Application
H = Heating Boiler
Boiler rating plate showing model number

6
RECEIVI G EQUIPME T
On receipt of the equipment, visually check for exter-
nal damage to the carton or the shipping crate. If either
is damaged, make a note on the Bill of Lading and
report the damage to the Carrier immediately. Remove
the boiler from the carton or the shipping crate.
On occasion, items are shipped loose. Be sure that
you receive the number of packages indicated on the
Bill of Lading.
When ordering parts, you must specify the Model and
Serial Number of the boiler. When ordering under war-
ranty conditions, you must also specify the date of
installation.
Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak boiler. If there
are any questions which this manual does not answer,
please contact the factory or your local Raypak repre-
sentative.
Claims for shortages and damages must be filed with
carrier by consignee. Permission to return goods must
be factory authorized and are subject to a stocking
charge.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defec-
tive replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.
CERTIFICATIO S
The Raypak hydronic boilers are design certified and
tested under the latest requirements of the American
National Standard, ANSI Z21.13. ach boiler has been
constructed and pressure tested in accordance with
the requirements of Section IV of the American Society
of Mechanical ngineers Code, and factory fire tested.
All models are National Board approved. Temperature
and pressure gauge is standard. Model 0133 has a 4-
pass heat exchanger, 1 tube per pass. Models
0181-1826 have 2-pass heat exchangers, 5 tubes first
pass, 4 tubes second pass. Models 2100-4001 have
2-pass heat exchangers, 9 tubes per pass. Models
926-4001 have optional single-pass heat exchangers
with cast iron headers only.
BOILER TYPES
Type H1 - Mechanical
Modulating, Models 133-1826
Central heating boiler with 150°-210°F mechanical
modulating gas valve(s). The number of valves varies
with the model size.
Type H2 - Motorized
Modulating, Models 514-4001
Central heating boiler with a motorized modulating gas
valve. Modulating controller optional.
Type H3 - 2-Stage Controls,
Models 181-4001
Central heating boiler with single 2-stage gas valve
and optional 2-stage controller.
Type H4 - On-Off Controls,
Models 181-4001
Central heating boiler with on-off firing.
Type H5 - Mechanical
Modulating, Models 181-1826
Central heating boiler with 110°-170°F mechanical
modulating gas valve(s).
Type H9 - 4-Stage, Models 514-
4001
Central heating boiler with 4-stage firing. Controller
optional.

7
I STALLATIO
Installation Codes
The installation must conform with these instructions
and the latest editions of the National Fuel Gas Code
ANSI Z223.1, the National lectric Code ANSI/NFPA
70 and local codes. All boiler installations must con-
form to ASM boiler code. Hot water pipes must be
installed with minimum clearances to combustible
material as required by code.
Installation Base
The boiler should be mounted on a level, non-com-
bustible surface. Boiler must not be installed on
carpeting. The boiler can be installed on a combustible
surface only when a suitable floor shield base is pro-
vided. Raypak offers an optional floor shield base
which can be factory installed on all indoor models
except Model 133; the Model 133 floor shield base is
shipped loose and must be installed by the contractor.
Do NOT use the shipping crate base as an installation
base.
In addition, the boiler shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.).
Clearances
OTE: The boiler should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.
Boiler Model No. Base Part No. Boiler Model No. Base Part No.
926*
1083*
1178*
1287*
1414*
1571*
1758*
962
1125
1223
1336
1468
1631
1826
001749
058313
058314
058315
058316
056199
056200
056201
056202
133
182/181
260/261
330/331
400/401
514
624
724
824
054597
054598
054599
054600
054601
058378
058379
059233
059234
059235
059236
059237
059238
059239
Table B: Combustible Floor Shield Ordering
Information
* Models with factory-installed floor shield as standard.
BOLD type indicates Low NOx models.
Fig. 2: Alternate ethod for Providing a Non-
Combustible Base
MODEL
133 181 to
401
514 to
824
926 to
1826
2100 to
4001
Table C: Clearances from Combustible Surfaces
All dimensions are in inches.
Derived from National Fuel Gas Code, Table 6.2.3(a)
*Vent includes factory-supplied drafthood and does not include field-
supplied vent systems above the drafthood. On Models 2100-4001
drafthood is built into boiler.
OTE: For Models 2100-4001, a factory-installed
floor shield is standard. Table B provides the floor
shield ordering information for other models.

8
OTE: Combustible floor shield is required when
boiler is to be installed on a combustible surface.
(See ordering information in Table B)
OTE: Servicing Clearances: Provide at least 24"
(Models 133-1826), 48" (Models 2100-4001) in front
of unit for removal and servicing of the Controls &
Burner Tray. Provide at least 18" on side opposite
water connections for deliming of Heat xchanger
Tubes.
OTE: The boiler shall be installed in a space large
in comparison to the size of the boiler. Large space
is defined as having a volume at least sixteen (16)
times the total volume of the boiler.
Table D: Reduction of Clearances to Protected
Surfaces
Derived from National Fuel Gas Code, Table 6.2.3(b)
Outdoor Boilers
These boilers are design certified for outdoor installa-
tion. Boilers must not be installed under an overhang
within three (3) feet from the top on the boiler. Three
(3) sides must be open in the area under the over-
hang. Roof water drainage must be diverted away
from the boilers with the use of gutters.
The point from where the flue products exit the boiler
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, win-
dow or gravity inlet to a building. The top surface of the
boiler shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet hor-
izontally.
High-Wind Conditions (Outdoor
Units Only)
In areas where high winds are frequent, it may be nec-
essary to locate the boiler a minimum of 3' from high
vertical walls, or install a wind break so the boiler is not
in direct wind current.
Combustion and Ventilation Air
(Indoor Units Only)
The boiler must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are 12 inches from ceiling for ventilation and
12 inches from the floor for combustion air as outlined
in Z223.1 - latest edition and any local codes that may
have jurisdiction.
Fig. 3: inimum Distances to Building Openings from
Where Flue Products Exit the Boiler

9
a. All Air From Inside The Building:
ach opening shall have a minimum net free
square inches as noted in Table .
b. All Air From Outdoors:
When air is supplied directly from outside of build-
ing, each opening shall have a minimum net free
square inches as noted in Table F.
CAUTIO : Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the boiler and void the warranty.
odel Sq. Inches odel Sq. Inches
133 136 1125 1125
182/181 181 1223 1223
260/261 264 1336 1337
330/331 334 1468 1467
400/401 399 1631 1630
514 512 1826 1826
624 627 2100 2100
724 726 2500 2499
824 825 3001 3000
962 962 3500 3500
4001 4000
odel Sq. Inches odel Sq. Inches
133 34 1125 282
182/181 46 1223 306
260/261 66 1336 335
330/331 84 1468 367
400/401 100 1631 408
514 128 1826 457
624 157 2100 525
724 182 2500 625
824 207 3001 750
962 241 3500 875
4001 1000
Table E: inimum Net Free Air from Inside Building
Table F: inimum Net Free Air from Outside Building
Venting
Outdoor Installations
Model 133
1. Remove the front (4) screws.
2. Line up outdoor top vent opening over heater vent
opening.
3. Lower outdoor top onto unit lining up slots in the
outdoor top with screw holes in jacket top.
4. Reinstall (5) screws to secure jacket top and out-
door top to unit.
Models 181-401 & 182-400
Outdoor Top Installation
Fig. 4: Installing Outdoor Top— odel 133
(Part of heater)
Fig. 5: Installing Outdoor Top— odels 181-401 & 182-
400

10
1. Remove jacket top panel.
2. Remove and discard inner stack adapter panel.
3. Install jacket top panel.
4. Insert tabs of outdoor top into keyholes located on
jacket top panel (4 places). See Detail A.
5. Snap tabs on outdoor top into the locked position
of the keyhole so the top will not pull out. See
Detail B.
Models 514-824
1. Lower outdoor top onto unit. Position top so it is
centered on unit from side to side and front to rear.
2. Tighten the (4) screws (as indicated in Fig. 8) until
they come in contact with the unit jacket top, then
evenly tighten all (4) screws to secure to unit.
Models 926-1758
Boilers are shipped with outdoor vent terminal factory
installed.
Indoor Installations
Model 133
1. Shut-off main electrical power switch to boiler.
2. Turn heater manual switch located in upper control
panel to the "OFF" position.
3. Shut-off gas supply and water supply to the boiler.
4. Mount drafthood on boiler and attach with the
sheet metal screws provided. Drafthood should be
positioned with the vent sensor located on the
front left side (see next page).
5. Remove plastic plug from left side of boiler jacket
and install the plastic grommet provided.
6. Route flue sensor wire harness through the grom-
met installed in Step 5.
7. Remove door and locate wire from roll-out sensor
to high limit with the male/female connector.
8. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.
Outdoor Top
(Shipped Loose with Heater)
Detail A Detail B
Fig. 6: Installing Outdoor Top— odels 181-401 & 182-
400
Fig. 7: Installing Outdoor Top— odels 514–824
JACKET TOP
FASTENING
SCREW
Fig. 8: Installing Outdoor Top Detail— odels 514–824

11
Fig. 9: Indoor Installation— odel 133
Models 181-401 & 182-400
Indoor Stack Installation
1. Remove the louvered jacket top by removing four
(4) #10 flathead screws.
2. If originally installed, remove outdoor top from the
louvered jacket top.
3. Place the inner stack adapter panel over the flue
collector inside the heater. Make sure the flanged
side of the flue opening is up.
4. Turn the stack (drafthood) upside down and set it
down bottom side up.
5. Turn the jacket top panel (removed in step 1)
upside down and place it over the stack.
6. Attach the three (3) mounting brackets to the stack
using the screws provided and the holes that are
pre-drilled in the stack. ake sure the brackets
are positioned with the flange near the top side
of the stack (see Fig. 10). Caution must be
taken not to over tighten and strip the screw
threads.

12
7. Turn the assembled stack and jacket top, rightside
up. The jacket top will be trapped between the
brackets and the top of the stack. Place the stack
over the inner stack adapter panel flanged hole
and lower the louvered jacket top panel back into
its original position. Reinstall the four (4) #10 flat-
head screws removed in step 1 above.
Models 181-401 & 182-400
1. Shut-off main electrical power switch to boiler.
2. Turn heater manual switch located in upper control
panel to the "OFF" position.
3. Shut-off gas supply and water supply to the boiler.
4. Mount drafthood on top of boiler as shown in Fig.
12. Drafthood should be positioned with the vent
sensor located on the front right side as shown.
5. Remove plastic plug from left side of boiler jacket
and install plastic grommet provided.
6. Route flue sensor wire harness through the grom-
met installed in Step 5.
7. Remove door and locate wire from roll-out sensor
to high limit with the male/female connector.
8. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.
Fig. 10: Indoor Installation— odels 181-401 & 182-400
Fig. 11: Boiler Before Drafthood Installation— odels
181-401 & 182-400
Fig. 12: Boiler After Drafthood Installation— odels
181-401 & 182-400
Models 514-824
Locate and assemble as shown in Fig. 13. Secure with
screws supplied in envelope in carton.

13
Fig. 13: Drafthood Installation— odels 514–824
Models 962-1826
Locate and assemble as shown in Fig. 14. Secure with
screws supplied in envelope in carton.
Models 2100-4001
These models have built-in drafthoods. For proper
operation, the drafthood outlet must be connected to
the venting system.
Vent Piping
Vent piping the same size or larger than the drafthood
outlet is recommended, however, when the total vent
height is at least 10 ft. (drafthood relief opening to vent
terminal), the vent pipe size may be reduced as spec-
ified in Chapter 10 of the latest edition of the National
Fuel Gas Code, ANSI Z223.1.
As much as possible, avoid long horizontal runs of
vent pipe and too many elbows. If installation requires
horizontal non-vertical runs, the vent pipe must have a
minimum of 1/4 inch per foot rise and should be sup-
ported at not more than 5 ft. intervals. Plumbers tape,
criss-crossed, will serve to space both horizontal and
vertical piping.
Gas vents supported only by the flashing and extend-
ing above the roof more than 5 ft. should be securely
guyed or braced to withstand snow and wind loads.
We recommend the use of insulated vent pipe spacers
through the roof and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which com-
plies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1.
The discharge opening must be a minimum of 2 ft. ver-
tically from the roof surface and at least 2 ft. higher
than any part of the building within 10 ft.
Vent stack shall be at least 5 ft. in vertical height above
the drafthood outlet. The vent cap location shall have
a minimum clearance of 4 feet horizontally from, and
in no case above or below, unless a 4-foot horizontal
distance is maintained, from electric meters, gas
meters regulators and relief equipment.
The weight of the vent stack or chimney must not rest
on boiler drafthood. Support must be provided in com-
pliance with applicable codes. The boiler top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Fig. 14: Drafthood Installation— odels 962–1826
WAR I G: Indoor boilers require a drafthood
that must be connected to a vent pipe and properly
vented to the outside. Failure to follow this
procedure can cause fire or fatal carbon monoxide
poisoning.

14
Type "B" double-wall or equivalent vent pipe is recom-
mended. However, single-wall metal vent pipe may be
used as specified in the latest edition of the National
Fuel Gas Code ANSI Z223.1.
Manifolds that connect more than one boiler to a com-
mon chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
manifold and the chimney. At no time should the area
be less than the area of the largest outlet.
At the time of removal of an existing boiler, the follow-
ing steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain-
ing connected to the common venting system are not
in operation.
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
(c) As much as possible, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
Fig. 15: Common Venting
hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga-
rette, cigar or pipe.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(g) Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When re-sizing any
portion of the common venting system, the com-
mon venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1.
For special venting applications that require reduced
vent sizes and through-the-wall venting, the Type D
Induced Draft Assembly can be used. Consult the fac-
tory or your local Raypak representative.
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
Fig. 16: Venting Clearances

15
Vent Damper Installation
(Models 133 Through 261)
Where Required
Location
The vent damper must be located in the vent so that it
serves only the appliance for which it is intended.
If improperly installed, a hazardous condition, such as
an explosion or carbon monoxide poisoning, could
result. Make certain that it is mounted in an accessible
location at least 6 inches from any combustible mate-
rial or the heat exchanger, and that the position
indicator is in a visible location.
The vent damper must be installed after the appliance
drafthood, as close to the drafthood as practicable,
and without modification of the drafthood.
On vertical vents, the vent damper may be mounted
with the actuator in any position. On horizontal vents,
do not mount the actuator either directly above or
directly below the vent pipe; mount the vent damper
actuator to the side of the vent.
The vent damper is set up for a continuous pilot sys-
tem. If the vent damper is installed on an Intermittent
Pilot or Direct Spark Ignition equipped system, the
energy savings of the vent damper can be improved
by plugging the hole in the vent damper blade using
the knockout plug, Part No. 105612R, provided in the
parts envelope.
DO NOT plug the hole if installing the vent damper on
a continuous pilot system as this will create a hazard.
Fig. 17: Vent Damper Installation ( odel 133 Drafthood
Shown)
WAR I G: Do not use thermally actuated vent
dampers on a modulating boiler. To do so may result
in asphyxiation. Use only a mechanically actuated
vent damper device that is electrically interlocked
with the modulating boiler operation.
HORIZONTAL INSTALLATION
TO BOILER D80B TOCHIMNEY
NO
NO
YES
YES
VERTICAL
INSTALLATION TO CHIMNEY
VENT DAMPER
TO BOILER
INSTALL VENT DAMPER
WITH ACTUATOR TO
SIDES OF VENT ONLY.
DO NOT MOUNT ABOVE
ORBELOW VENT.
FLOW >
ACTUATOR MAY BE
INSTALLED IN ANY
POSITION ON VERTICAL
PIPE
????? ?????? ??????? ?????????? ?? ??? ?? ???????? ?????????? ?? ???? ?????
D80B
N. O. N. C.
END
SWITCH
C.
1K2
1K1
R
1K3
12345
1R
BLACK ORANGE RED YELLOW BLUE
THERMOSTATOR
CONTROLLER
LIMIT OPTIONAL LIMIT
LOCATION
TRANSFORMER
DUAL VALVE
COMBINATION
GAS CONTROL OR
IGNITION SYSTEM
1
1
L1
L2
(HOT)
POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED
Fig. 18: Horizontal/Vertical Vent Damper Installation
Fig. 19: Vent Damper General Wiring Diagram

16
CAUTIO : Install the vent damper to service only
the single appliance for which it is intended. if
improperly installed, a hazardous condition, such as
an explosion or carbon monoxide poisoning, could
result.
Vent Damper
ormal Operation Summary
For safe, efficient operation, the vent damper and all
flue product carrying areas of the appliance must be
checked annually, with particular attention given to
deterioration from corrosion or other sources. Check
vent damper operation as follows:
1. When the boiler is off, check that the vent damper
position indicator points to the closed position. (See
figure below.)
2. Turn the thermostat or controller up to call for heat
and check that the vent damper indicator points to the
open position. (See figure below.)
3. Turn the thermostat or controller down again and
check that the vent damper position indicator returns
to the closed position.
OTE: The vent damper must be inspected at least
once a year by a trained, experienced service
technician. The name of the person who originally
installed your vent damper is shown on the
installation label. Damper must be in open position
when boiler main burners are operating.
Damper Position Indicator
Damper Open Damper Closed
Fig. 20: Vent Damper Position Indicator
FFIKAL® RVGP
Fig. 21: Connection Diagram for Effikal® Vent Damper
Plumbing
Gas Supply Connections
Gas piping must have a sediment trap ahead of the
boiler gas controls, and a manual shut-off valve locat-
ed outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
OTE: Do not use teflon tape on gas line pipe
thread. A flexible sealant approved for the fuel being
used is recommended.
Fig. 22: Plumbing

17
Table G: aximum Equivalent Pipe Length
A minimum of 7" W.C. and a maximum of 10.5" W.C.
upstream pressure, under load and no-load condi-
tions, must be provided for natural gas, or a minimum
of 12" W.C. and a maximum of 13" for propane.
Gas Pressure Regulator
The gas pressure regulator is preset nominally at 4"
W.C. for natural gas, and 11" W.C. for propane.
Between the gas valve and the burners is a 1/8" pipe
plug. The pressure at this point, taken with a manome-
ter, should be about 3.7" W.C. for natural gas and
10.5" W.C. for propane. Low NOx models should be
3.9" W.C., natural gas only. If an adjustment is need-
ed, turn adjustment screw clockwise to increase
pressure, or counter-clockwise to decrease pressure.
For boilers with mechanical modulation gas valves
(Type H1 and H5) or two-stage gas valves (Type H3),
the gas pressure regulator is preset and sealed, and
not field adjustable. Pressure tap is provided on the
outlet side of the gas valve for measurement of gas
pressure in the manifold.
Venting of Diaphragm Gas
Components
Gas valves that are equipped with a gas bleed must be
vented to the outdoors as required by the National
Fuel Gas Code. Under NO circumstances shall bleed
lines terminate in the gas utilization equipment flue or
exhaust system.
General
Boiler should be located so that any water leaks will
not cause damage to any adjacent areas or structures.
See piping diagrams for proper water connections for
the type of boiler and system.
Pump Selection
In order to ensure proper hydraulics in your hydronic
heating system, adequate pump size must be select-
ed. We recommend that the pump be sized for 20°F
Delta T whenever possible. (Delta T is the temperature
Fig. 23: Bleed Line Connection Location
CAUTIO : The boiler and its manual shut-off valve
must be disconnected from the gas supply during
any pressure testing of that system at test pressures
in excess of 1/2 PSIG. Dissipate test pressure in
the gas supply line before reconnecting the boiler
and its manual shut-off valve to gas supply line.
FAILUR TO FOLLOW THIS PROC DUR MAY
DAMAG TH GAS VALV . OV R PR SSUR D
GAS VALV S AR NOT COV R D BY
WARRANTY. The boiler and its gas connections
shall be leak tested before placing the appliance in
operation. Use soapy water for leak test do NOT use
open flame.
*Low NOx units not available for propane.
Bleed Line
Connection
Vent Line
Connection

18
RDHRDHLEDOM
SIZE GPM TPFTGPMTPFTCONN GPM T P FT GPM T P FT CONN
133* 22 10 14.7 10 22 3.3 1-1/4"
182/181 45 7 9.2 20 15 1.8 1-1/2"
260/261 45 10 9.4 20 22 1.9 1-1/2"
330/331 45 12 9.6 20 28 1.9 1-1/2"
400/401 45 15 9.8 20 33 2.0 1-1/2"
514 90 9 9 40 21 1.8 2"
624 90 12 9.5 40 26 1.9 2"
724 90 13 10 40 30 2.0 2"
824 90 15 10.5 40 34 2.1 2"
926 90 17 11 40 38 2.2 21/2" 200 8 9.7 90 17 2.1 3"
962 90 18 11 40 40 2.2 2 1/2" 200 8 9.7 90 18 2.1 3"
1083 90 20 12 45 40 3.1 2 1/2" 200 9 10.3 90 20 2.3 3"
1125 90 21 12 47 40 3.3 21/2" 200 9 10.3 90 20 2.3 3"
1178 90 22 12.5 49 40 3.8 2 1/2" 200 10 11 90 21 2.4 3"
1223 90 22 12.5 51 40 4.0 2 1/2" 200 10 11 90 22 2.4 3"
1287 90 24 13.2 53 40 4.5 2 1/2" 200 11 11.7 90 23 2.5 3"
1336 90 24 13.2 55 40 4.9 2 1/2" 200 11 11.7 90 24 2.5 3"
1414 90 26 14 58 40 5.8 2 1/2" 200 12 12.290 26 2.7 3"
1468 90 27 14 61 40 6.4 2 1/2" 200 12 12.290 27 2.7 3"
1571 90 29 14.5 65 40 7.5 2 1/2" 200 13 13 90 29 2.8 3"
1631 90 30 14.5 68 40 8.3 2 1/2" 200 13 13 90 30 2.8 3"
1758 90 32 15.4 73 40 10.0 2 1/2" 200 14 14.7 90 32 3 3"
1826 90 34 15.4 76 40 10.8 2 1/2" 200 15 14.7 90 33 3 3"
2100 200 17 14.8 90 39 3.2 3" 400 9 18 180 19 4 4"
2500 200 21 15.8 103 40 4.4 3" 400 10 18.8 180 23 4.1 4"
3001 200 25 16.7 124 40 6.7 3" 400 12 19.5 180 27 4.3 4"
3500 200 29 17.5 145 40 9.5 3" 400 14 20.5 180 32 4.5 4"
4001 200 33 18.7 166 40 13.0 3" 400 16 21.5 180 36 4.7 4"
MAXIMUM AND MINIMUM FLOW RATES
2-PASS HEAT EXCANGER 1-PASS HEAT EXCHANGER
NIMXAMNIMXAM
GPM Flow rates limited by maximum acceptable velocity through heat exchanger tubes. May be increased by 10% for closed heating
systems.
* 4 Pass Heat Exchanger
BOLD TYPE indicates Low NOx models.
difference between the inlet and outlet water when the
boiler is firing at full rate). For some boilers, the Delta
T is more than 20°F (22°-33°F) at the recommended
flow rates.
Feedwater Regulator
We recommend that a feedwater regulator be installed
and set at 12 PSIG minimum pressure. Install a check
valve or back flow device upstream of the regulator,
with a manual shut-off valve. Leave the valve open.
Piping—Heating Boilers
We recommend that all high points be vented and that
purge valves and a bypass valve be installed. A boiler
installed above radiation level must be provided with a
low water cut-off device. The boiler, when used in con-
junction with a refrigeration system, must be installed
so that the chilled medium is piped in parallel with the
boiler with appropriate valves to prevent the chilled
medium from entering the boiler.
Recommended Purge Manifolds for
Typical Hydronic System Hookups
The boiler piping system of a hot water heating boiler
connected to heating coils located in air handling units
where they may be exposed to refrigerated air circulat-
ing, must be equipped with flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.
Temperature & Pressure Gauge
The temperature & pressure gauge is standard equip-
ment on all hydronic heating and hot water supply
boilers. All temperature & pressure gauges are factory
mounted in the in/out header except for residential
boilers, Models 133 and 181-401. On these models
the temperature & pressure gauge is shipped loose for
field installation, and located in the outlet water con-
nection. All fittings required to mount gauge to piping
system are supplied by others.
Table H: aximum and inimum Flow Rates

19
CONTROLLER SENSOR (LESS THAN 4-STAGE)
CONTROLLER SENSOR (4-STAGE OR MODULATION)
5’ MAX
5’ MAX
Fig. 24: Single Boiler Primary/Secondary Piping— odels 133–4001
Note: xpansion tanks (supplied by others) should be installed per manufacturer's instructions.

20
MAXIMUM OF 12”OR
4 PIPE DIAMETERS
CONTROLLER SENSOR
5’ MAX
Reverse return piping is a proper method of manifolding multiple boiler hook-ups to ensure balanced flow through each boiler. Valves on
supply and return are needed to isolate any boiler, as required.
Fig. 25: ultiple-Boiler– Reverse Return Hook-Up— odels 133–4001